US4263049A - Fibre-reinforced product and method of preparing same - Google Patents

Fibre-reinforced product and method of preparing same Download PDF

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Publication number
US4263049A
US4263049A US06/082,547 US8254779A US4263049A US 4263049 A US4263049 A US 4263049A US 8254779 A US8254779 A US 8254779A US 4263049 A US4263049 A US 4263049A
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product
fibres
set forth
cementitious
eucalyptus
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US06/082,547
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Karl E. Hansen
Peder Pedersen
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Rockwool AS
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Rockwool International AS
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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04Waste materials; Refuse
    • C04B18/18Waste materials; Refuse organic
    • C04B18/24Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
    • C04B18/248Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork from specific plants, e.g. hemp fibres
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Definitions

  • This invention relates to a cementitious product reinforced by cellulosic fibres and optionally synthetic fibres.
  • Products made from asbestos cement present many advantageous properties, such as a high bending strength, excellent resistance against attack by chemicals and good ageing properties.
  • asbestos cement products suffer from the serious drawback that the manufacture and handling of such products present such serious health problems that is may be expected that the use of asbestos fibres as reinforcement in cementitious products will be prohibited in a few years.
  • the strength mentioned above is unsatisfactory because a bending strength of at least 165 kp/cm 2 is considered to be a minimum one in order to permit the replacement of asbestos cement products by products reinforced by cellulosic fibres.
  • the reinforcing fibres are at least partly composed of eucalyptus fibres.
  • eucalyptus fibres should be understood as discrete fibres obtained by defibration of eucalyptus wood.
  • eucalyptus fibres which are suitable for use in the cementitious product of the invention are fibres of Eucalyptus saligna, Eucalyptus globulus and Eucalyptus camaldulensis.
  • fibres which have been prepared by a sulphate process and which have been bleached.
  • Cellulosic fibres were dispersed in 1 liter water and 5 liters additional water and optionally rock wool fibres were added. Subsequently, the mixture thus obtained was stirred for 5 minutes before Portland cement was added.
  • a polyelectrolyte (“Reten 123 x") was added in an amount of 4.2 ppm. Stirring was continued for one additional minute and the mixture was then transferred to a sheet mould comprising a net covered by a sheet of filter paper. The mixture was then dewatered by suction and the layer thus formed on the sheet of filter paper was compressed at increasing pressures (1 minute at 5 kp/cm 2 , 1 minute at 10 kp/cm 2 and 1 minute at 15 kp/cm 2 ).
  • the plates thus prepared were stored at room temperature and a relative humidity of 100% and the bending strength and density were measured.
  • the cementitious products of the invention preferably contain eucalyptus fibres in an amount of 3-10% by weight based on the weight of the cementitious product.
  • the fibrous reinforcement comprises both eucalyptus fibres and synthetic mineral fibres, e.g. rock wool fibres.
  • a cementitious product comprising such a combination of fibres as fibrous reinforcement presents excellent properties for practical use.
  • the toughness of the product is high and, therefore, it can be handled without break.
  • a composition is particularly useful for the manufacture of roofing plates which should be capable of withstanding blows and impacts without breakage.
  • the latter is preferably present in an amount of 5-10% by weight based on the total weight of the reinforced product.
  • mineral fibres comprises fibres prepared from naturally occurring minerals.
  • synthetic mineral fibres are rock wool fibres, glass fibres and slag fibres.
  • the invention also relates to a method of preparing a fibre-reinforced cementitious product as described above.
  • the method of the invention comprises the steps of disperging eucalyptus fibres preferably in an amount of 3-10% by weight based on the weight of the final product and optionally mineral fibres in water by stirring, adding while continuously stirring the dispersion, a cement and optionally a polyelectrolyte and moulding and storing the mixture thus formed so as to form the desired product.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Civil Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Botany (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
  • Reinforcement Elements For Buildings (AREA)
  • Artificial Filaments (AREA)
  • Laminated Bodies (AREA)

Abstract

A fibre-reinforced cementitious product comprising a fibre reinforcement, at least partly consisting of eucalyptus fibres.

Description

BACKGROUND OF THE INVENTION
This invention relates to a cementitious product reinforced by cellulosic fibres and optionally synthetic fibres.
It is well known to use asbestos fibres for the reinforcement of cementitious products. Thus, asbestos fibres find widespread use in the manufacture of asbestos cement roofing plates, such as plates sold under the trade name "Eternit".
Products made from asbestos cement present many advantageous properties, such as a high bending strength, excellent resistance against attack by chemicals and good ageing properties.
However, asbestos cement products suffer from the serious drawback that the manufacture and handling of such products present such serious health problems that is may be expected that the use of asbestos fibres as reinforcement in cementitious products will be prohibited in a few years.
It is well known to utilize a mixture of asbestos fibres and cellulosic fibres as reinforcement in the production of asbestos cement products.
However, attempts to fully replace asbestos fibres by cellulosic fibres in fibre-reinforced cementitious products and in amounts of from 0.5 to 20% by weight have failed to produce products having satisfactory strength properties. Thus, the maximum obtainable binding strength (after storage for 4 weeks) for fibre-reinforced cement products comprising pine-wood cellulosic fibres is only about 165 kp/cm2. Such bending strength is obtained by using reinforcing fibres in an amount of 4% by weight and this strength does not increase significantly when the amount of fibres is increased.
The strength mentioned above is unsatisfactory because a bending strength of at least 165 kp/cm2 is considered to be a minimum one in order to permit the replacement of asbestos cement products by products reinforced by cellulosic fibres.
SUMMARY OF THE INVENTION
Surprisingly it has been found that a specific type of cellulosic fibres are capable of producing a high reinforcing effect when used as reinforcing fibres in cementitious products and that the bending strength of such fibre-reinforced cementitious products is considerably higher than the above mentioned minimum value.
Thus, in the fibre-reinforced cementitious product of the invention the reinforcing fibres are at least partly composed of eucalyptus fibres.
The term "eucalyptus fibres" should be understood as discrete fibres obtained by defibration of eucalyptus wood.
By using eucalyptus fibres in fibre-reinforced cementitious products a bending strength of above 220 kp/cm2 (after storage for 4 weeks) has been obtained. Thus, the strength is increased by more than 30% compared to products reinforced by pine-wood fibres.
Examples of different types of eucalyptus fibres which are suitable for use in the cementitious product of the invention are fibres of Eucalyptus saligna, Eucalyptus globulus and Eucalyptus camaldulensis.
It is preferred to use fibres which have been prepared by a sulphate process and which have been bleached.
The reinforcing effect of both eucalyptus fibres and pine-wood fibres on cementitious products has been investigated by tests. These tests were carried out in the following manner:
Cellulosic fibres were dispersed in 1 liter water and 5 liters additional water and optionally rock wool fibres were added. Subsequently, the mixture thus obtained was stirred for 5 minutes before Portland cement was added.
After stirring for 5 minutes, a polyelectrolyte ("Reten 123 x") was added in an amount of 4.2 ppm. Stirring was continued for one additional minute and the mixture was then transferred to a sheet mould comprising a net covered by a sheet of filter paper. The mixture was then dewatered by suction and the layer thus formed on the sheet of filter paper was compressed at increasing pressures (1 minute at 5 kp/cm2, 1 minute at 10 kp/cm2 and 1 minute at 15 kp/cm2).
Subsequently, 5 layers of filter paper were placed on each side of the fibre cement plate formed and the plate was compressed for 2 minutes at a pressure of 60 kp/cm2.
The plates thus prepared were stored at room temperature and a relative humidity of 100% and the bending strength and density were measured.
The composition of the tested fibre cement samples and their properties are reported in Table 1.
                                  TABLE 1                                 
__________________________________________________________________________
                                           Corrected Bending              
                                           Strength after                 
                 Measured Bending Strength kp/cm.sup.2                    
                                           Storage for 4                  
           Number of                                                      
                 After After  After        Weeks and at a                 
Reinforcing Fibres                                                        
           Measure-                                                       
                 Storage                                                  
                       Storage                                            
                              Storage                                     
                                     Density,                             
                                           Density of 1.7                 
Type  Amount, %                                                           
            ments                                                         
                 for 1 Week                                               
                       for 2 Weeks                                        
                              for 4 Weeks                                 
                                     g/cm.sup.3                           
                                           g/cm.sup.3                     
__________________________________________________________________________
Eucalyptus-                                                               
      1    8     111 ± 13                                              
                       157 ± 12                                        
                              138 ± 15                                 
                                     1.88 ± 0.03                       
                                           113 ± 14                    
fibres                                                                    
Eucalyptus-                                                               
      2    8     118 ± 9                                               
                       143 ± 16                                        
                              155 ± 20                                 
                                     1.88 ± 0.03                       
                                           128 ± 15                    
fibres                                                                    
Eucalyptus-                                                               
      3    8     153 ± 8                                               
                       153 ± 4                                         
                              172 ± 11                                 
                                     1.81 ± 0.01                       
                                           150 ± 9                     
fibres                                                                    
Eucalyptus-                                                               
      4    8     177 ± 5                                               
                       199 ± 12                                        
                              208 ± 14                                 
                                     1.78 ± 0.02                       
                                           191 ± 14                    
fibres                                                                    
Eucalyptus-                                                               
      5    8     193 ± 10                                              
                       198 ± 10                                        
                              226 ± 8                                  
                                     1.73 ± 0.03                       
                                           219 ± 12                    
fibres                                                                    
Eucalyptus-                                                               
      10   2     147 ± 7                                               
                         --     --   1.58 ± 0.02                       
                                           169 ± 6*                    
fibres                                                                    
Eucalyptus-                                                               
      20   10    125 ± 10                                              
                       148 ± 10                                        
                              183 ± 12                                 
                                     1.35 ± 0.02                       
                                           290 ± 12                    
fibres                                                                    
Eucalyptus-                                                               
      30   10    91 ± 11                                               
                       101 ± 9                                         
                              117 ± 10                                 
                                     1.08 ± 0.03                       
                                           291 ± 12                    
fibres                                                                    
None  0    10    86 ± 46                                               
                         --   134 ± 32                                 
                                     1.78 ± 0.11                       
                                           122 ± 22                    
Pine-Wood                                                                 
      1    8     123 ± 17                                              
                       146 ± 30                                        
                              124 ± 27                                 
                                     1.73 ± 0.11                       
                                           124 ± 39                    
Fibres                                                                    
Pine-Wood                                                                 
      2    8     130 ± 6                                               
                       149 ± 3                                         
                              141 ± 10                                 
                                     1.72 ± 0.10                       
                                           139 ± 23                    
Fibres                                                                    
Pine-Wood                                                                 
      3    8     180 ± 17                                              
                       176 ± 3                                         
                              170 ± 11                                 
                                     1.77 ± 0.02                       
                                           156 ± 11                    
Fibres                                                                    
Pine-Wood                                                                 
      4    8     177 ± 16                                              
                       163 ± 5                                         
                              169 ± 13                                 
                                     1.72 ± 0.08                       
                                           162 ± 17                    
Fibres                                                                    
Pine-Wood                                                                 
      5    8     148 ± 18                                              
                       175 ± 21                                        
                              171 ± 27                                 
                                     1.72 ± 0.02                       
                                           165 ± 23                    
Fibres                                                                    
__________________________________________________________________________
 *After storage for 1 week.                                               
The data set forth in Table 1 show that the reinforcing effect of eucalyptus fibres increases with increasing fibre contents up to about 5% and that no significant improvement of the strength is obtained at higher fibre contents. Therefore, the cementitious products of the invention preferably contain eucalyptus fibres in an amount of 3-10% by weight based on the weight of the cementitious product.
In a preferred embodiment of the fibre-reinforced cementitious product of the invention the fibrous reinforcement comprises both eucalyptus fibres and synthetic mineral fibres, e.g. rock wool fibres. A cementitious product comprising such a combination of fibres as fibrous reinforcement presents excellent properties for practical use.
Thus, the toughness of the product is high and, therefore, it can be handled without break. Thus, such a composition is particularly useful for the manufacture of roofing plates which should be capable of withstanding blows and impacts without breakage.
This is evidenced by the work required to cause breakage which work can be determined by integrating the area below a deflection curve obtained by measuring the deflection of a specimen supported at its ends at varying loads, the abscissa defining the deflection and the ordinate the load.
By testing different materials it has been found that the work required to cause breakage is 5.5 for a cementitious product containing 5% by weight of eucalyptus fibres and 7.7 for a product containing 5% by weight of eucalyptus fibres and 5% by weight of rock wool fibres. These figures are based on the definition that the work required to cause breakage of a product consisting of cement is 1.
By using the above mentioned combination of fibres as a reinforcement in cementitious products, a product is obtained which is resistant to the formation of shrinkage cracks which may occur when the reinforcing fibres are eucalyptus fibres only. Consequently, the weathering resistance of the product and in particular the frost resistance is increased by using said combination of fibres.
When using both eucalyptus and synthetic mineral fibres as reinforcement, the latter is preferably present in an amount of 5-10% by weight based on the total weight of the reinforced product.
The term "mineral fibres" comprises fibres prepared from naturally occurring minerals. Examples of synthetic mineral fibres are rock wool fibres, glass fibres and slag fibres.
The invention also relates to a method of preparing a fibre-reinforced cementitious product as described above.
The method of the invention comprises the steps of disperging eucalyptus fibres preferably in an amount of 3-10% by weight based on the weight of the final product and optionally mineral fibres in water by stirring, adding while continuously stirring the dispersion, a cement and optionally a polyelectrolyte and moulding and storing the mixture thus formed so as to form the desired product.

Claims (15)

We claim:
1. An asbestos-free, fiber-reinforced cementitious product comprising a major portion of a cementitious material and a reinforcing quantity of a fibrous material including a sufficient amount of eucalyptus fibers to provide a final product having improved bending strength characteristics.
2. A cementitious product as set forth in claim 1 wherein said eucalyptus fibers are present in an amount of from 3% to 10% by weight based on the total weight of the product.
3. A cementitious product as set forth in claim 1 wherein a sufficient quantity of said eucalyptus fibers are present to provide a bending strength of at least 165 kp/cm2 after storage for four weeks.
4. A cementitious product as set forth in claim 1 wherein said fibrous material also includes synthetic fibers.
5. A cementitious product as set forth in claim 4 wherein said synthetic fibers are present in an amount of from 5% to 10% by weight based on the total weight of the product.
6. A cementitious product as set forth in claim 2 wherein said fibrous material also includes synthetic fibers.
7. A cementitious product as set forth in claim 6 wherein said synthetic fibers are present in an amount of from 5% to 10% by weight based on the total weight of the product.
8. A method of preparing an asbestos-free, fiber-reinforced cementitious product comprising:
dispersing in water a reinforcing quantity of a fibrous material including a sufficient amount of eucalyptus fibers to provide a final product having improved bending strength characteristics;
stirring said dispersion while adding cementitious material thereto;
molding the mixture thus formed; and
storing the molded product.
9. A method as set forth in claim 8 wherein a polyelectrolyte is added along with the cementitious material during said stirring step.
10. A method as set forth in claim 8 wherein said fibrous material also includes synthetic fibers.
11. A method as set forth in claim 8 wherein said eucalyptus fibers are present in an mount of from 3% to 10% by weight based on the total weight of the product.
12. A method as set forth in claim 8 wherein a sufficient quantity of said eucalyptus fibers are present to provide a bending strength of at least 165 kp/cm2 after storage for four weeks.
13. A method as set forth in claim 10 wherein said synthetic fibers are present in an amount of from 5% to 10% by weight based on the total weight of the product.
14. A method as set forth in claim 11 wherein said fibrous material also includes synthetic fibers.
15. A method as set forth in claim 14 wherein said synthetic fibers are present in an amount of from 5% to 10% by weight based on the total weight of the product.
US06/082,547 1978-10-10 1979-10-09 Fibre-reinforced product and method of preparing same Expired - Lifetime US4263049A (en)

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DK4507/78 1978-10-10
DK450778A DK145118C (en) 1978-10-10 1978-10-10 FIBER ARMED CEMENT PRODUCT AND PROCEDURES FOR PRODUCING THE SAME

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JP (1) JPS5556059A (en)
AT (1) AT379361B (en)
BE (1) BE879275A (en)
CA (1) CA1128556A (en)
CH (1) CH642899A5 (en)
DE (1) DE2940623C2 (en)
DK (1) DK145118C (en)
ES (1) ES484895A0 (en)
FI (1) FI65226C (en)
FR (1) FR2440343A1 (en)
GB (1) GB2033887B (en)
IT (1) IT1123787B (en)
LU (1) LU81764A1 (en)
NL (1) NL7907375A (en)
NO (1) NO147419C (en)
SE (1) SE431199B (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4369201A (en) * 1980-03-04 1983-01-18 Harald Kober Method of manufacturing reinforced fibers for mineral structural materials, and a structural element of a fiber-reinforced mineral structural material
US4985119A (en) * 1987-07-01 1991-01-15 The Procter & Gamble Cellulose Company Cellulose fiber-reinforced structure
US6164034A (en) * 1998-08-31 2000-12-26 Poly Proximates, Inc. Fiber-reinforced molded plastic roofing unit and method of making the same

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS59131551A (en) * 1983-01-16 1984-07-28 松下電工株式会社 Manufacture of inorganic hardened body
DE3517778A1 (en) * 1985-05-17 1987-01-15 23 Szamu Allami Epitoeipari Va METHOD FOR THE PRODUCTION OF BODIES, IN PARTICULAR OF COMPONENTS
DE10046387C1 (en) * 2000-09-20 2002-05-23 In Ter Consult Greiz Ingenieur Production of wood concrete products used in tropical regions of Africa comprises mixing Portland cement, cement with grinding additives or blast furnace cement, finely divided additives, water, binding regulator, pressing and drying

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US827977A (en) * 1906-01-10 1906-08-07 Paul Dickinson Composition of matter.
US844530A (en) * 1906-09-22 1907-02-19 Franz Musil Edler Von Mollenbruck Manufacture of cement.
US3062669A (en) * 1957-01-28 1962-11-06 Dilnot Sidney Light weight aerated concrete
US3438853A (en) * 1966-02-10 1969-04-15 Armstrong Cork Co Process of curing hardboard containing wood fibers and portland cement
US3969567A (en) * 1973-03-13 1976-07-13 Tac Construction Materials Ltd. Improvements in and relating to board products

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR873830A (en) * 1941-03-28 1942-07-21 New reinforced cement system with fiber reinforcement
GB1425035A (en) * 1972-03-22 1976-02-18 Univ Toronto Orthopaedic structure
DE2461781C2 (en) * 1974-12-30 1982-09-23 Cape Boards and Panels Ltd., Uxbridge Process for the production of an asbestos-free, refractory molded body
BE857870A (en) * 1976-08-17 1977-12-16 Commw Scient Ind Res Org FIBER REINFORCED CEMENT COMPOSITIONS

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US827977A (en) * 1906-01-10 1906-08-07 Paul Dickinson Composition of matter.
US844530A (en) * 1906-09-22 1907-02-19 Franz Musil Edler Von Mollenbruck Manufacture of cement.
US3062669A (en) * 1957-01-28 1962-11-06 Dilnot Sidney Light weight aerated concrete
US3438853A (en) * 1966-02-10 1969-04-15 Armstrong Cork Co Process of curing hardboard containing wood fibers and portland cement
US3969567A (en) * 1973-03-13 1976-07-13 Tac Construction Materials Ltd. Improvements in and relating to board products

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4369201A (en) * 1980-03-04 1983-01-18 Harald Kober Method of manufacturing reinforced fibers for mineral structural materials, and a structural element of a fiber-reinforced mineral structural material
US4985119A (en) * 1987-07-01 1991-01-15 The Procter & Gamble Cellulose Company Cellulose fiber-reinforced structure
US6164034A (en) * 1998-08-31 2000-12-26 Poly Proximates, Inc. Fiber-reinforced molded plastic roofing unit and method of making the same
US6290885B1 (en) 1998-08-31 2001-09-18 Poly Proximates, Inc. Method of making a fiber-reinforced molded plastic roofing unit

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DE2940623C2 (en) 1986-02-13
DK450778A (en) 1980-04-11
FI65226C (en) 1984-04-10
NO147419C (en) 1983-04-06
LU81764A1 (en) 1980-01-24
ATA658779A (en) 1985-05-15
FR2440343A1 (en) 1980-05-30
CH642899A5 (en) 1984-05-15
DE2940623A1 (en) 1980-04-24
AT379361B (en) 1985-12-27
FI793108A7 (en) 1980-04-11
IT7926366A0 (en) 1979-10-10
DK145118B (en) 1982-09-06
NO147419B (en) 1982-12-27
NL7907375A (en) 1980-04-14
SE431199B (en) 1984-01-23
SE7908333L (en) 1980-04-11
JPS5556059A (en) 1980-04-24
FI65226B (en) 1983-12-30
NO793239L (en) 1980-04-11
CA1128556A (en) 1982-07-27
IT1123787B (en) 1986-04-30
DK145118C (en) 1983-02-07
GB2033887A (en) 1980-05-29
GB2033887B (en) 1983-01-19
FR2440343B1 (en) 1983-01-07
BE879275A (en) 1980-02-01
ES8102067A1 (en) 1980-12-16
JPS6156179B2 (en) 1986-12-01
ES484895A0 (en) 1980-12-16

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